Technical Field:
[0001] The present invention relates to a method of producing aerated soap from aerated
molten soap. More particularly, it relates to a method of producing aerated soap while
preventing shrinkage or development of sink marks on cooling.
Background Art:
[0002] Applicant of the present invention has previously proposed in JP-A-10-195494 a method
of producing aerated soap which comprises solidifying molten soap containing a large
number of bubbles in a cavity of a mold, wherein the step of solidification is carried
out in a hermetically closed cavity. The method aims at preventing development of
voids or depressions in solidified soap.
[0003] According to this production method, outside air not being allowed to enter the cavity,
the solidified soap hardly suffers from void or depression development. However, there
still is room for further improvement for preventing soap volume reduction due to
contraction of aeration gas on cooling molten soap and for preventing resultant shrinkage
and/or development of sink marks.
Disclosure of the Invention:
[0004] Accordingly, an object of the present invention is to provide a method of producing
aerated soap while preventing shrinkage and/or sink mark development on cooling in
solidifying aerated molten soap.
[0005] The present invention accomplishes the above object by providing a method for producing
aerated soap which comprises solidifying molten soap having a large number of bubbles
dispersed therein in a mold cavity having a prescribed shape, wherein 1.05 or more
times as much molten soap as the volume of aerated soap is fed to the cavity and solidified
in a compressed state, wherein the compression ratio of the gaseous components in
the molten soap is from 1.08 to 2.5.
Brief Description of the Drawings:
[0006]
Fig. 1(a), Fig. 1(b), and Fig. 1(c) are sequential diagrams showing the steps involved
in a first embodiment of the method for producing aerated soap according to the invention.
Fig. 2 is a perspective of a mold used in a second embodiment of the method for producing
aerated soap according to the invention.
Fig. 3(a), Fig. 3(b), Fig. 3(c) and Fig. 3(d) are sequential diagrams showing the
steps involved in the second embodiment of the method for producing aerated soap according
to the present invention.
Best Mode for Carrying out the Invention:
[0007] The present invention will be described with reference to its preferred embodiments
by referring to the accompanying drawings. Figs. 1(a) to (c) show in sequence the
steps involved in the first embodiment of the production method according to the present
invention.
[0008] As shown in Fig. 1(a), an apparatus used in this embodiment has a mold composed of
a lower, mold 1 and an upper mold 2 and a feeding section 3. The lower mold 1 is made
of a rigid material such as metal and has a cavity 11 facing up. The cavity 11 has
a concave shape in conformity to the bottom and sides of an aerated soap as a product.
A plurality of interconnecting holes 12 are made in the bottom of the cavity 11 which
interconnect the cavity 11 and the outside of the lower mold 1. A clamping mechanism
13 is attached to the sides of the lower mold 1 which clamps the lower mold 1 and
the upper mold 2.
[0009] The upper mold 2 is also made of a rigid material such as metal. The upper mold 2
is composed of a lid 21, a compressing part 22 which is fitted to the lower side of
the lid 21 and the lower side of which is shaped to the upper contour of the aerated
soap, a pressing part 23 fitted to the upper side of the lid 21, and a fitting part
24 which is fitted to the pressing part 23 with clearance and engaged with the clamping
mechanism 13 of the lower mold 1.
[0010] The feeding section 3 has an injection nozzle 31, a switch valve 32, a cylinder 33,
and a piston 34 disposed in the cylinder 33. The piston 34 is designed to slide back
and forth in the cylinder 33. The volume of molten soap to be fed' is decided by the
push distance of the piston 34. Molten soap is stored in a storage tank (not shown)
and circulating through a circulating duct (not shown) while passing through the storage
tank. The flow of the molten soap is switched by the switch valve to feed the circulating
molten soap into the cylinder 33. Separation of the molten soap into gas and liquid
is prevented effectively by circulating the molten soap.
[0011] Production of aerated soap by use of an apparatus having the above-described construction
will be described. Molten soap having a great number of bubbles dispersed therein
is delivered to the cylinder 33 of the feeding section 3. Then, the piston 34 is pushed
over a prescribed distance to push out the molten soap, whereby the molten soap 4
is fed to the cavity 11 of the lower mold 1 through the injection nozzle 31. Molten
soap having a great number of bubbles dispersed therein can be prepared by, for example,
the method described in JP-A-11-43699, filed by the present applicant, col. 2, line
15 to col. 5, line 1.
[0012] Various gases are useful for aerating molten soap. In particular, an inert gas, especially
a non-oxidizing inert gas such as nitrogen gas, is effective to prevent the molten
soap components from being oxidatively decomposed on heating to generate offensive
odors, etc.
[0013] The molten soap is fed into the cavity 11 in an amount at least 1.05 time, preferably
1.1 or more time, still preferably 1.15 or more time, as much as a target volume as
an aerated soap. Shrinkage and sink mark development due to cooling of the molten
soap can be effectively prevented by feeding the recited volume of molten soap, assisted
by the compression of the molten soap as described later. It is predictable that shrinkage
or sink mark formation on cooling would hardly occur where a larger amount of molten
soap than a set volume of an aerated soap is fed and compressed. The characteristic
of the present invention resides in the finding that such an unpredictably small excess
of volume, i.e., 1.05 or more time as much as the set volume of an aerated soap suffices
to effectively prevent shrinkage or sink mark development on cooling. The upper limit
of the molten soap volume to be fed is decided appropriately according to the volumetric
proportion of bubbles present in the molten soap. For example, molten soap containing
a relatively large proportion of bubbles will shrink to a larger degree on cooling
so that the upper limit of the volume to be fed will be raised. On the other hand,
where molten soap has a relatively small proportion of bubbles, the upper limit of
the volume to be fed is relatively small because the degree of shrinkage on cooling
will not be so high. Taking into consideration that the total volume of bubbles in
the molten soap according to this embodiment is about 5 to 70%, a preferred upper
limit of the volume to be fed is three times, particularly two times, the volume of
aerated soap. The upper limit, of the volume to be fed being three times, particularly
two times, the volume of aerated soap is also preferred for preventing soap from losing
its shape during the production or use on account of loss of hardness.
[0014] The volume of molten soap varies with pressure and temperature. The term "volume
of molten soap" as used herein means the volume at 25°C under atmospheric pressure.
[0015] It is preferred that the molten soap be maintained at a temperature of 55 to 80°C,
particularly 60 to 70°C, when fed to the cavity 11 to prevent the molten soap from
solidifying at the tip of the injection nozzle while preventing oxidation of soap
and deterioration of perfume.
[0016] In this connection, the molten soap is preferably injected into the cavity 11 at
a temperature higher than the melting point by 1 to 20°C, particularly 2 to 5°C, for
the same reason.
[0017] It is preferred for the molten soap injected into the cavity 11 to have a viscosity
of 0.001 to 50 Pa·s, particularly 0.01 to 10 Pa·s, especially 0.02 to 5 Pa·s. At a
viscosity above the upper limit, injecting molten soap into the cavity 11 is difficult
and needs a pump with greater output, which makes the production equipment larger.
The lower limit of the viscosity practically depends on the viscosity of water contained
in the molten soap. The viscosity of molten soap is measured as follows. Molten soap
is poured in a cylindrical tube having an inner diameter of 10 mm and a length of
1880 mm with its downstream end open. The other end (upstream end) of the tube is
provided with a pressure gage. The pressure at a shear rate of 300
-1 is read, and the melt viscosity is calculated from the reading according to Hagen-Poiseuille
equation. Hagen-Poiseuille equation is described, e.g., in Mcheal R Lindeburg,
Engineering Training Reference Manual 8th Ed., pp. 17-5 to 17-6, Professional Publications, Inc., Belmont, CA. The measuring
temperature is the same as the temperature of the molten soap actually injected into
the cavity.
[0018] Upon completion of feeding the molten soap 4, the upper side of the lower mold 1
is closed with the upper mold 2, and the fitting part 24 fitted to the upper mold
2 is engaged by the clamping mechanism 13 attached to the lower mold 1. Thus, the
two molds are fixed. Then, as shown in Fig. 1(b), the pressing part fitted to the
upper mold 2 is pressed down by a prescribed pressing means (not shown), such as a
pressure cylinder, to compress the molten soap 4 in the cavity 11 to a set volume
of an aerated soap as a product. The molten soap is let to solidify in this compressed
state. These operations effectively prevent development of shrinkage and sink marks
on cooling the molten soap to provide cakes of aerated soap with satisfactory appearance.
[0019] The pressure (gauge pressure) for compressing the molten soap is usually about 0.005
to 0.3 MPa, particularly about 0.05 to 0.2 MPa, while varying according to how many
times as much as the set volume of an aerated soap the fed molten soap volume is.
[0020] The compression ratio of the molten soap, i.e., the compression ratio of the gaseous
components in the molten soap (volume of gaseous components before compression/volume
of gaseous components after compression) is 1.08 to 2.5, preferably 1.1 to 2, from
the standpoint of preventing development of shrinkage or sink marks on cooling, reducing
the cooling time, and improving productivity. The gaseous components in the molten
soap include the gas used for aerating molten soap, steam contained in molten soap,
and the like.
[0021] The solidification time of the molten soap can be shortened by cooling the lower
mold 1 by a prescribed means, for example, a coolant such as water. As a matter of
course, spontaneous cooling will do. Where the mold is cooled with water, the water
temperature is preferably about 5 to 25°C for preventing non-uniform dispersion of
bubbles on cooling.
[0022] The molten soap is preferably solidified so that the resulting aerated soap may have
an apparent density of 0.4 to 0.85 g/cm
3, particularly 0.6 to 0.8 g/cm
3. This is preferred for securing the fluidity of the molten soap, improving the cooling
efficiency, improving releasability of aerated soap from the cavity 11, and improving
appearance of the resulting soap. Such a solidified state can be achieved by, for
example, feeding aerated molten soap made of 55 ml (under atmospheric pressure) of
nitrogen gas and 90 ml of a soap composition into the cavity 11 at 64°C, compressing
the aerated molten soap to 120 ml, and letting the molten soap to solidify in this
compressed state. The method of measuring the apparent density of aerated soap will
be described in Examples hereinafter given.
[0023] It is also preferred that the molten soap is solidified in such a manner that the
proportion of bubbles (pores) having a size of 1 to 300 µm in the total pore volume
in the resulting aerated soap (hereinafter referred to as a pore volume fraction)
may be 80% or more for improving latherability and preventing the soap from getting
sodden or swollen in contact with water. Such a solidified state can be obtained by
aerating a soap composition by means of, for example, an aeration apparatus Euromix
MDFO supplied by Ebara Corp. at a rotor's rotation speed of 1000 kPa (500 rpm), and
solidifying the arated molten soap in the cavity by cooling while keeping the molten
soap in a compressed state. The method of measuring the pore volume fraction of aerated
soap will be described in Examples hereinafter given.
[0024] On completion of solidification of the molten soap, the engagement of the clamping
mechanism 13 attached to the lower mold 1 and the fitting part 24 attached to the
upper mold 2 is released, and the upper mold 2 is removed as shown in Fig. 1(c). The
aerated soap 5 is taken out of the cavity 11 of the lower mold 1 by using a prescribed
holding means, for example, a vacuum gripper. To facilitate removal of the aerated
soap from the mold, gas such as air may be blown into the cavity 11 through the interconnecting
holes 12 made in the bottom of the cavity 11.
[0025] The aerated soap thus obtained assumes a satisfactory outer appearance with neither
shrinkage nor sink marks which may have developed on cooling the molten soap. Further,
the bubbles inside the aerated soap are spherical. Having spherical bubbles, the soap
exhibits moderate water repellency, adding improvement on conventional aerated soap
having the demerit of easily getting sodden or swollen in contact with water. -
[0026] Compounding components which can make up the aerated soap include fatty acid soaps,
nonionic surface active agents, inorganic salts, polyols, non-soap type anionic surface
active agents, free fatty acids, perfumes, and water. If desired, such additives as
antimicrobials, pigments, dyes, oils, and plant extracts, can be added appropriately.
[0027] The second embodiment of the present invention will then be described by referring
to Figs. 2 and 3. The second embodiment will be described only with reference to differences
from the first one. With reference to the particulars that are not described hereunder,
the description on the first embodiment applies appropriately. In Figs. 2 and 3 the
same members as in Fig. 1 are given the same numerals used in Fig. 1.
[0028] The mold shown in Fig. 2 is a split mold made of a pair of split pieces, a first
piece 1A and a second piece 1B. Each piece is made of a rigid material such as metal
and has a rectangular block shape with a depression 11 A or 11B in its central portion.
The depressions 11A and 11B are shaped to provide a cavity (not shown) in agreement
with the contour of a soap to be produced when the first piece 1A and the second piece
1B are joined together on their parting faces PL.
[0029] The second piece 1B has a nozzle insert hole 2B piercing through the outer periphery
around the depression 11B in the thickness direction. The diameter of the nozzle insert
hole 2B increases gradually toward the back side of the second piece 1B. The first
piece 1A has a gate 2A of semicircular section engraved on part of its parting face
PL. The gate 2A connects the edge side E and the depression 11A of the first piece
1A. A piston P mating the shape of the gate 2A is inserted in the gate 2A The piston
P is made of metal, plastic, etc. and designed to slide in the gate 2A. The nozzle
insert hole 2B and the gate 2A are made in the respective pieces in such a configuration
as to provide a tunnel connecting the nozzle insert hole 2B, the gate 2A, and the
cavity when the first piece 1A and the second piece 1B are joined together on their
parting faces PL. While not shown, an air vent is provided on the parting face PL
of the second piece 1B. While not shown, a passageway for cooling water circulation
is made in the blocks constituting the pieces 1A and 1B.
[0030] Loops L of a buckle mechanism are attached to both sides of the first piece 1A, and
hooks F of the buckle mechanism are attached to both sides of the second piece 1B.
The loops L and the hooks F are positioned so that they are engaged with each other
with the first and the second pieces 1A and 1B joined on their parting faces PL.
[0031] The mold shown in Fig. 2 is used as fitted to the production apparatus shown in Fig.
3. The production apparatus has a mold unit 4A and a molten soap injection unit 3A.
The mold is fitted above a base plate 40 of the mold unit 4A as shown in Fig. 3(a).
The base plate 40 has an upright support plate 41 for the first piece 1A and an upright
support plate 42 for the second piece 1B. The support plate 41 has fixed to the inner
side thereof a cylinder 44 having a piston 43. The cylinder 44 is fixed so that the
piston 43 may slide in the direction perpendicular to the support plate 41. The tip
of the piston 43 is fixed to the back of the first piece 1A. Accordingly, the first
piece 1A is a horizontally movable half of the mold. The first piece 1A is fitted
with its gate 2A side down. An L-shaped cylinder holding member 45 is attached to
the lower part of the back of the first piece 1A. The horizontal part of the cylinder
holding member 45 has a cylinder 47 with a piston 46. The cylinder 47 is fitted to
allow the piston 46 to slide vertically. The tip of the piston 46 is connected to
the piston P disposed in the first piece 1A.
[0032] The second piece 1B is fitted to the support plate 42 with its nozzle insert hole
2B down and its depression 11B facing the depression 11A of the first piece 1A. As
is understood from Fig. 3(a), the second piece 1B is a fixed half of the mold. The
molten soap injection unit 3A is provided in the rear of the second piece 1B. The
injection unit 3A comprises an injection nozzle 31, a switch valve 32, a cylinder
33, and a piston 34 disposed in the cylinder 33. The injection nozzle 31, being shaped
in conformity with the shape of the nozzle insert hole 2B made in the second piece
1B, is inserted in the nozzle insert hole 2B. A gate pin 35 is provided to slide inside
the injection nozzle 31. The injection of molten soap through the injection nozzle
31 to the cavity is controlled through push and pull of the gate pin 35. The switch
valve 32 serves to connect the cylinder 33 to either a circulating duct 36 which passes
through a storage tank (not shown) or the injection nozzle 31. In the state shown
in Fig. 3(a), the cylinder 33 connects to the injection nozzle 31, with the connection
between the cylinder 33 and the circulating duct 36 shut off.
[0033] The method of producing aerated soap by use of the production apparatus shown in
Fig. 3 is described below. The cylinder 44 of the mold unit 4A operates to push the
piston 43 forward to join the first piece 1A and the second piece 1B to close the
split mold. The buckle mechanism (see Fig. 2) is fastened to clamp the split mold.
Water is made to circulate through the above-mentioned cooling water passageway made
in both split mold pieces. The cylinder 47 operates to draw back the piston 46, whereby
part of the piston P connected to the piston 46 is drawn out of the first piece 1A.
In the injection unit 3A, on the other hand, while the piston 34 is in a pushed state,
the switch valve 32 operates to connect the cylinder 33 to the circulating duct 36.
The piston 34 is then drawn back to deliver a predetermined amount of molten soap
into the cylinder 33. The switch valve 32 then operates to cut the connection between
the cylinder 33 and the circulating duct 36 and connect the cylinder 33 to the injection
nozzle 31 as shown in Fig. 3(a). Subsequently, the piston 34 is pushed to push the
molten soap 4 out of the cylinder 33. It follows that the molten soap 4 is injected
under pressure into the cavity 11C through the injection nozzle 31 and the gate 2A
(see Fig. 2). Similarly to the first embodiment, the volume of the molten soap to
be injected is at least 1.05 time the target volume of an aerated soap. This expression
does not mean that a greater amount than 1.05 time is preferred as is preferred in
the first embodiment. In other words, 1.05 or more time as much molten soap as the
target volume is enough. The molten soap in the cavity 11C is compressed to a set
volume of an aerated soap by this operation of injection under pressure. Unlike the
first embodiment, the present embodiment does not require separation of a compression
step from the molten soap feeding step. That is, compression of molten soap is effected
in the feeding step. Accordingly, the production method of the second embodiment achieves
an increased production efficiency over that of the first embodiment. Besides, the
production apparatus used in the second embodiment involves a shorter stroke in the
machine movement than that used in the first embodiment, furnishing another merit
that the size of the apparatus can be reduced.
[0034] Upon completion of injecting a prescribed volume of molten soap under pressure, the
gate pin 35 is pushed to shut off the connection between the injection nozzle 31 and
the cavity 11C as shown in Fig. 3(b). The cylinder 47 then operates to push the piston
46 thereby pushing the piston P connected to the piston 46 into the gate 2A (see Fig.
2). As a result, the molten soap remaining in the gate 2A is injected into the cavity
11C.
[0035] The mold unit 4A is then withdrawn (moved to the right in the drawing) whereby the
injection unit 3A is separated from the second piece 1B as shown in Fig. 3(c), and
the molten soap in the cavity 11C is cooled and solidified in the compressed state.
As previously stated, the pieces 1A and 1B have been cooled to a prescribed temperature
by the circulating cooling water to accelerate the cooling solidification of the molten
soap in the cavity 11C. Since the molten soap has been injected under pressure in
a volume 1.05 or more time the set volume of an aerated soap and compressed, shrinkage
and sink mark development on cooling solidification of the molten soap are prevented.
[0036] On solidifying the molten soap, the engagement of the buckle mechanism which has
been fixing the split mold pieces 1A and 1B is relieved. The cylinder 44 operates
to draw back the piston 43 to separate the pieces 1A and 1B as shown in Fig. 3(d).
The aerated soap 5 is then taken out of the cavity by a prescribed holding means (not
shown).
[0037] The present invention is by no means limited to the above-described embodiments.
For example, while in the first embodiment aerated soaps are produced by the use of
the lower mold 1 and the upper mold 2, the lower mold 1 may be composed of a plurality
of pieces according to the contour of a desired aerated soap product.
[0038] The mold used in the first and the second embodiments may be replaced with a hollow
member made of a synthetic resin such as polyethylene, polypropylene, polycarbonate
or polyester; a flexible thin metal plate; a flexible rubber material, etc. Such a
hollow member may be used as inserted in the mold used in the second embodiment, and
molten soap is fed into the hollow member and solidified in a compressed state. In
this case, there is an advantage that the hollow member serves as a packaging container
of the resulting aerated soap.
EXAMPLES 1 TO 4 AND COMPARATIVE EXAMPLE 1
[0039] Molten soap having a great number of bubbles dispersed therein was prepared from
the compounding components shown in Table 1 below in accordance with the method described
in JP-A-11-43699
supra. Nitrogen gas was used for aeration.
TABLE 1
Compounding Component of Molten Soap |
Part by Weight |
sodium laurate |
30.0 |
sodium cocoyl isetionate |
2.0 |
sodium lauroyl lactate |
5.0 |
polyoxyethylene monolaurate |
2.0 |
lauric acid |
5.0 |
glycerol |
20.0 |
sodium chloride |
1.5 |
perfume |
1.5 |
water |
32.0 |
[0040] Aerated soaps were produced from the prepared molten soap according to the steps
shown in Figs. 1 (a) through (c). The molten soap was fed to the cavity 11 of the
lower mold 2. The temperature and the injected volume of the molten soap were as shown
in Table 2. The upper side of the lower mold 1 was closed with the upper mold 2, and
the molten soap was compressed to a set volume (120 cm
3) by the compressing part 22 of the upper mold 2. The compression ratio of the molten
soap was as shown in Table 2. In this compressed state the lower mold was cooled with
cooling water at 5 to 15°C for 3 to 15 minutes to solidify the molten soap.
[0041] On completion of solidification of the molten soap, the upper mold 2 was removed.
The aerated soap was taken out of the cavity 11 by means of a vacuum gripper while
blowing compressed air into the cavity 11 through the interconnecting holes 12 made
through the bottom of the cavity 11. There was thus obtained an aerated soap as a
final product.
[0042] The apparent density and the pore volume fraction of the resulting aerated soap were
measured according to the following methods. The outer appearance of the soap was
evaluated based on the following standard. The results obtained are shown in Table
2.
Measurement of apparent density
[0043] A rectangular parallelopiped specimen having known side lengths (e.g., 10 to 50 mm)
was cut out of the resulting aerated soap and weighed. The weight was divided by the
volume to give the apparent density. The volume was calculated from the three side
lengths. The weight measurement was made with an electron balance. The measurement
was made at 25°C±3°C and a relative humidity of 40 to 70%.
Measurement of pore volume fraction
[0044] An aerated soap was rapidly cooled to -196°C and cut at -150°C. The cut surface was
observed in vacuo at -150°C under an electron microscope Crio SEM JSM-5410/CRU, manufactured
by JEOL Hightech Co., Ltd. The accelerating voltage was 2 kV, and a secondary electron
image was used as detection signals. The diameter of pores was measured on a micrograph
(magnification 500X), and a pore volume fraction was calculated from the measured
diameter.
Evaluation of appearance
[0045] The appearance was observed with the naked eye and graded according to the following
standard.
A Equal to the cavity shape
B Substantially equal to the cavity shape
C Sink marks were observed as compared with the cavity shape.
TABLE 2
|
Example |
Comparative Example 1 |
1 |
2 |
3 |
4 |
|
Injected Volume (%*) |
118 |
125 |
112 |
135 |
100 |
Molten Soap |
Temp. (°C) |
64 |
65 |
55 |
70 |
50 |
|
Compression Ratio |
1.49 |
1.64 |
1.45 |
1.86 |
1.0 |
|
Apparent Density (g/cm3) |
0.64 |
0.62 |
0.75 |
0.6 |
0.85 |
Aerated Soap |
Pore Volume Fraction (%) |
100 |
100 |
100 |
100 |
100 |
|
Appearance |
A |
A |
B |
B |
C |
Note: * Based on a set volume of an aerated soap |
[0046] As is obvious from the results shown in Table 2, the aerated soaps obtained in Examples
exhibit satisfactory appearance with neither shrinkage nor sink marks due to cooling.
While not shown in the Table, the aerated soaps obtained in Examples gave off no offensive
odor attributed to heating of the molten soap. To the contrary, the aerated soaps
of Comparative Example showed partial missing or sink marks ascribed to cooling.
EXAMPLES 5 TO 7 AND COMPARATIVE EXAMPLE 2
[0047] Molten soap having a large number of bubbles dispersed therein was prepared from
the same compounding components as used in Example 1 in accordance with the same procedure
as in Example 1. Aerated soaps were produced from the prepared molten soap by use
of the mold shown in Fig. 2 according to the steps shown in Figs. 3(a) through (d).
The temperature and the injected volume of the molten soap were as shown in Table
3. Each split mold pieces had been cooled with cooling water at 5 to 15°C. The molten
soap cooling time was 3 to 15 minutes. Otherwise, the same procedures as in Example
1 were followed to obtain aerated soaps. The apparent density and the pore volume
fraction of the resulting aerated soaps were measured, and the appearance of the soaps
was evaluated in the same manner as in Example 1. The results obtained are shown in
Table 3.
TABLE 3
|
Example |
Comparative Example2 2 |
5 |
6 |
7 |
|
Injected Volume (%*) |
110 |
106 |
116 |
100 |
Molten Soap |
Temp. (°C) |
64 |
64 |
64 |
64 |
|
Compression Ratio |
1.41 |
1.22 |
1.59 |
0.99 |
|
Apparent Density (g/cm3) |
0.78 |
0.75 |
0.76 |
0.71 |
Aerated Soap |
Pore Volume Fraction (%) |
100 |
100 |
100 |
100 |
|
Appearance |
A |
A |
A |
C |
Note: *Based on a set volume of an aerated soap |
[0048] As is apparent from the results shown in Table 3, the aerated soaps obtained in Examples
exhibit satisfactory appearance with neither shrinkage nor sink marks due to cooling.
While not shown in the Table, the aerated soaps obtained in Examples gave off no offensive
odor attributed to heating of the molten soap. To the contrary, the aerated soaps
of Comparative Example showed partial missing or sink marks ascribed to cooling. In
particular as is apparent from comparison between Example 7 and Comparative Example
2, it is clearly understood that shrinkage and sink mark development on cooling can
be prevented by feeding and compressing 1.05 or more time as much molten soap as the
volume of the aerated soap in the cavity.
Industrial Applicability:
[0049] According to the method of the present invention for producing aerated soap, aerated
molten soap can be solidified while effectively preventing shrinkage and/or sink mark
development on cooling.
[0050] In particular, use of an inert gas for aerating molten soap effectively prevents
generation of offensive odors attributed to heating of the molten soap.
1. Verfahren zur Herstellung von mit Gas durchsetzter Seife, das das Erstarren geschmolzener
Seife mit einer großen Anzahl von darin verteilten Blasen in einem Gusshohlraum mit
einer vorgeschriebenen Form umfasst, wobei 1,05 oder mehr Mal soviel geschmolzene
Seife wie das Zielvolumen der mit Gas durchsetzten Seife dem Hohlraum zugeführt wird
und in einem komprimierten Zustand erstarrt wird, wobei das Kompressionsverhältnis
der gasförmigen Komponenten in der geschmolzenen Seife von 1,08 bis 2,5 beträgt.
2. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei 1,05
oder mehr mal soviel geschmolzene Seife wie das Zielvolumen der mit Gas durchsetzten
Seife unter Druck in den Hohlraum eingespritzt wird und die geschmolzene Seife in
dem Hohlraum auf das Volumen der mit Gas durchsetzten Seife mittels des Einspritzens
unter Druck komprimiert wird und in dem komprimierten Zustand erstarrt wird.
3. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei 1,05
oder mehr mal soviel geschmolzene Seife wie das Zielvolumen der mit Gas durchsetzten
Seife in den Hohlraum eingespritzt wird, und die geschmolzene Seife in dem Hohlraum
auf das Volumen der mit Gas durchsetzten Seife durch ein vorgeschriebenes Kommpressionsmittel
komprimiert wird und in dem komprimierten Zustand erstarrt wird.
4. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei die
geschmolzene Seife geschmolzene Seife ist, die mit einem inerten Gas durchsetzt wurde.
5. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei die
geschmolzene Seife in den Hohlraum unter einer Temperatur von 55 bis 80°C eingespritzt
wird.
6. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei die
geschmolzene Seife erstarrt wird, um mit Gas durchsetzte Seife mit einer scheinbaren
Dichte von 0,4 bis 0,85g/cm3 bereitzustellen.
7. Verfahren zur Herstellung von mit Gas durchsetzter Seife nach Anspruch 1, wobei die
geschmolzene Seife erstarrt wird, um mit Gas durchsetzte Seife zur Verfügung zu stellen,
die Blasen mit einer Größe von 1 bis 300 µm in einem Verhältnis von 80% oder mehr
am Gesamtvolumen der Blasen enthält.
1. Procédé de fabrication de savon aéré qui comprend le fait de faire se solidifier le
savon fondu comportant un grand nombre de bulles dispersées dans celui-ci dans une
cavité de moule ayant une forme prescrite, où 1,05 fois ou plus de savon fondu que
le volume cible du savon aéré est fourni à ladite cavité et solidifié dans un état
comprimé, où le rapport de compression des composants gazeux dans le savon fondu est
de 1,08 à 2,5.
2. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel 1,05 fois
ou plus de savon fondu que le volume cible du savon aéré est injecté dans ladite cavité
sous pression, et ledit savon fondu dans ladite cavité est comprimé au volume du savon
aéré par ladite injection sous pression et solidifié dans l'état comprimé.
3. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel 1,05 fois
ou plus de savon fondu que le volume cible du savon aéré est fourni à ladite cavité,
et ledit savon fondu dans ladite cavité est comprimé au volume du savon aéré par un
moyen de compression prescrit, et solidifié dans l'état comprimé.
4. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel ledit savon
fondu est du savon fondu qui a été aéré avec un gaz inerte.
5. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel ledit savon
fondu est injecté dans ladite cavité à une température de 55 à 80 °C.
6. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel ledit savon
fondu est solidifié pour fournir du savon aéré ayant une densité apparente de 0,4
à 0,85 g/cm3.
7. Procédé de fabrication de savon aéré selon la revendication 1, dans lequel ledit savon
fondu est solidifié afin de fournir du savon aéré contenant des bulles ayant une taille
de 1 à 300 µm dans une proportion de 80 % ou plus dans le volume total des bulles.